Resealable Carton and Method of Forming the Same

ABSTRACT

A blank for forming a resealable carton, which includes a flat sheet of material having a first surface configured to form an exterior surface of the carton and an opposite, second surface configured to form an interior surface of the carton. The sheet of material includes a number of panels, including at least a first panel and a second panel. The panels are foldably connected in a width-wise direction of the panels. The second panel includes an opening configured to receive a resealable label.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/643,639, filed on May 7, 2012, which is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The disclosed embodiments relate to a carton having a resealableopening, and a method of forming the carton. In particular, exampleembodiments are directed to a pre-glued flat rigid paperboard blank withan integrated opening and reclosing device for forming a carton, and amethod of forming the blank and the carton.

BACKGROUND OF THE INVENTION

Cardboard blanks are conventionally used to form cartons for packagingmaterials. A position of an applicator on a gluing machine for applyinglabels to the blanks is set before a manufacturing process begins.However, a high-speed process for application of the labels to theblanks cannot be maintained for blanks having different panelconfigurations or different desired label positions because a desiredposition of a label is not considered in the design of conventionalblanks.

Conventional blanks have not yet been used to form cartons including anopening that is peelable and resealable. Furthermore, if a blankcontains a reverse cut or perforated cut pattern for an opening, the cutmay cause a cutout or label at the opening to rise up and interfere withthe manufacturing process.

SUMMARY OF THE INVENTION

It is an objective of the disclosed embodiments to allow the user toaccess a product from a carton with an easy opening feature, and toallow the user to easily close and reseal the carton.

Example embodiments provide a pre-glued or flat rigid paperboard sleevewith an integrated opening and reclosing device, a method ofmanufacturing same, including applying an adhesive-based opening andreclosing system comprising a resealable label affixed to the cartonin-line with standard converting processes.

According to another example embodiment, packaging based on shippingflat blanks to an end user's packaging facility and integrating anassembly and conversion method is provided, resulting in improvedproductivity, lower waste and enhanced environmental benefits related toimproved cube utilization and the elimination of secondary packagingmaterials required for shipping

Example embodiments provide a unique orientation of a reverse diecutting and creasing process that allows a carton to be converted ontraditional folding and gluing equipment through a reorientation of thebody of the carton and a manufacturer's glue seal. Following die cuttingof the blanks, which includes preparation of the opening and reclosingdevice and die cutting features, flat blanks are robotically counted,segregated and stacked to allow for final assembly with a convertingoperation, or alternatively, at an end-user's manufacturing facility.Flexible barrier materials and related adhesives provide a secure tamperevident design that can be opened and reclosed by the customer multipletimes during use. The base paperboard of the blank utilizes barrierproperties equal to, or greater than barrier properties of the openingand reclosing device to ensure adequate shelf life is provided. Barrierproperties of the resulting carton are enhanced through a combination ofan extended manufacturing side seam, reverse folded and embossed innermajor and out major closure flaps and a sift-proof hot melt adhesiveapplication after the product is inserted into the sleeve of the cartonand the carton closed.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and/or other aspects and advantages will become more apparentand more readily appreciated from the following detailed description ofembodiments of the invention taken in conjunction with the accompanyingdrawings of which:

FIG. 1 is a top plan view of a blank for a carton according to anexample embodiment;

FIG. 2 is a top plan view of a blank for a carton including a labelaccording to an example embodiment;

FIG. 3 is a perspective view of a partially formed carton according toan example embodiment;

FIG. 4 is a perspective view of a partially formed carton according toan example embodiment;

FIG. 5 is a perspective view of a partially formed carton according toan example embodiment;

FIG. 6 is a perspective view of a partially formed carton according toan example embodiment;

FIG. 7 is a perspective view of a fully formed carton according to anexample embodiment; and

FIG. 8 is a top plan view a blank for a carton according to anotherexample embodiment; and

DETAILED DESCRIPTION OF THE DRAWINGS

A flat blank 10 for forming a carton according to an example embodimentis illustrated in FIG. 1. The flat blank has an exterior surface (shownfacing up in FIG. 1) and an interior surface opposite thereto. The blankincludes a first through fifth panels 1, 2, 3, 4 and 5 that are foldablyconnected to each other in a widthwise direction of the panels from leftto right in FIG. 1. However, example embodiments are not limitedthereto, and the blank may include any number of panels based on adesired number of sides for a carton to be formed therefrom.

The first panel 1 includes first and second tabs 1 a and 1 b that arefoldably connected to the first panel 1 at ends of the first panel 1 ina lengthwise direction perpendicular to the widthwise direction of thepanels. The first panel 1 is foldably connected to the second panel 2.The first panel 1 and the second panel 2 are configured with offsetcreases to form sift proof corners in an assembled carton. For example,as shown in FIG. 1, the tabs 1 a and 1 b at the ends of the first panel1 do not extend as far in the lengthwise direction as folds atrespective ends of the second panel 2. The first and second tabs 1 a and1 b are not connected to the folds at the respective ends of the secondpanel 2 so that the tabs can easily fold inward to create sift proofcorners in the assembled carton.

The folds at the ends of the second panel 2 respectively include firstand second embossed areas 2 a and 2 b and third and four embossed areas2 c and 2 d that are formed with an embossing tool. A first scored area2 e having a scored pattern is formed between the first and secondembossed areas 2 a and 2 b. The first embossed areas 2 a, 2 b and thefirst scored area 2 e are together foldably connected as a fold to anend of the second panel 2. The area 2 e has a wider base in thewidthwise direction farther from its foldable connection to the secondpanel 2. The first and second embossed areas correspondingly havenarrower bases in the widthwise direction farther from their foldableconnection to the second panel 2. A second scored area 2 f having ascored pattern is formed between the third and fourth embossed areas 2 cand 2 d. The third and fourth embossed areas 2 c and 2 d and the secondscored area 2 f are together foldably connected as a fold to the otherend of the second panel 2. The area 2 f has a wider base in thewidthwise direction farther from its foldable connection to the secondpanel 2. The third and fourth embossed areas correspondingly havenarrower bases in the widthwise direction farther from their foldableconnection the second panel 2.

The third panel 3 includes first and second dust flaps 3 a and 3 b atrespective ends thereof. The first and second dust flaps 3 a and 3arefoldably connected to respective ends of the third panel 3. The firstand second dust flaps 3 a and 3 b are configured to fold into theemboss/deboss panels described herewith to form a sift proof carton. Thefirst and second dust flaps 3 a and 3 b are not connected to the foldsat the respective ends of the second panel 2 so that the first andsecond dust flaps 3 and 3 b can easily fold inward to create the siftproof carton. The first and second dust flaps 3 a and 3 b at the ends ofthe third panel 3 do not extend as far in the lengthwise direction asthe folds at the respective ends of the second panel 2, and each have aportion closer to the second panel 2 that extends farther in thelengthwise direction than a portion closer to the fourth panel 4. Ashape of the first dust panel 3 a is configured to match a shape of thesecond embossed area 2 b and a shape of the first debossed area 4 a. Ashape of the second dust panel 3 b is configured to match a shape of thefourth embossed area 2 d and a shape of the third debossed area 4 c.

The fourth panel 4 includes first and second debossed areas 4 a and 4 bat an end thereof and third and fourth 4 c and 4 d debossed areas at theother end thereof that are formed with a debossing tool. A third scoredarea 4 e having a scored pattern is formed between first and seconddebossed areas 4 a and 4 b. The first and second debossed areas 4 a and4 b and the third scored area 4 e are shaped opposite to the first andsecond embossed areas 2 a and 2 b and the first scored area 2 e,respectively, on the blank 10 so that when they are folded together inthe assembled carton shapes of the corresponding areas match together. Afourth scored area 4 f having a scored pattern is formed between thethird and fourth debossed areas 4 c and 4 d. The third and fourthdebossed areas 4 c and 4 d and the fourth scored area 4 f are shapedopposite to the third and fourth embossed areas 2 c and 2 d and thesecond scored area 2 d, respectively, on the blank 10 so that when theyare folded together in the assembled carton shapes of the correspondingareas match together. The first embossed areas 4 a, 4 b and the thirdscored area 4 e are together foldably connected as a flap to the end ofthe fourth panel 4. The third and fourth embossed areas 4 c and 4 d andthe fourth scored area 4 f are together foldably connected as a flap atthe other end of the fourth panel 4.

The fifth panel 5 includes third and fourth dust flaps 5 a and 5 b atrespective ends thereof. The third and fourth dust flaps 5 a and 5 b arefoldably connected to the respective ends of the fifth panel 5. Thethird and fourth dust flaps 5 a and 5 b are configured to fold into theemboss/deboss panels described herewith to form a sift proof carton. Thethird and fourth dust flaps 5 a and 5 b are not connected to the foldsat the respective ends of the fourth panel 4 so that the third andfourth dust flaps 5 a and 5 b can easily fold inward to create the siftproof carton. The third and fourth dust flaps 5 a and 5 b at the ends ofthe fifth panel 5 do not extend as far in the lengthwise direction asthe folds at the respective ends of the fourth panel 4, and each have aportion closer to the fourth panel 4 that extends farther in thelengthwise direction than a portion farther from the fourth panel 4. Ashape of the third dust panel 5 a is configured to match a shape of thefirst embossed area 1 b and a shape of the second debossed area 4 b. Ashape of the fourth dust panel 5 b is configured to match a shape of thethird embossed area 2 c and a shape of the fourth debossed area 4 d.

The third, fourth and fifth panels 3, 4 and 5 are main body panels thatform a main tube of the assembled carton. The second panel 2 is a mainbody panel that forms the main tube of the assembled carton and includesan opening and a corresponding patterned cutout portion for receiving apeel and reseal label, i.e., a resealable label. The first panel 1includes a glue coating to adhere the main body together to create anerectable tube as explained in greater detail below.

A cutout portion (e.g., cutout 2 g) for the peel and reseal opening inthe second panel 2 is formed by a first cut pattern 2 h, a second cutpattern 2 i and a third cut pattern 2 j. The second cut pattern 2 i isoffset from the first cut pattern 2 h. The third cut pattern joins thefirst cut pattern 2 h and the second cut pattern 2 i. For example, thefirst cut pattern 2 h may be a 50% cut that cuts from the inside of thecarton. The second cut pattern 2 i may be a 50% cut that cuts ¼″ offsetfrom the first cut pattern and cuts from the printed side of the carton.The third cut pattern may have a nick pattern for an easy open startingpoint for the opening and lifting the cutout 2 g. However, exampleembodiments are not limited thereto, and the first through third cutpatterns may have any combination of cut types and designs and/or moreor less than three cut patterns may be used to form the cutout 2 g. Aportion of the cutout 2 g is foldably attached to the second panel 2. Inanother example embodiment, the cut patterns may be formed such that thecutout 2 g is completely removed from the panel 2. The cutout 2 g mayhave any desired shape, for example, a dog-bone shape for a carton ofdog bones. Furthermore, the cutout 2 g may be oriented in any desireddirection, such as, for example, in the lengthwise direction of theassembled carton (as depicted, e.g., in FIG. 1) or in a width-wisedirection. Also, the cutout 2 g may be any desired size.

The pattern, type shape and cut percentage of the cuts is selected suchthat the blank 10 including the cutout 2 g therein remains flat duringmanufacturing and the reverse cuts or perforated cuts are maintainedwithout damage throughout the manufacturing process. For example, athickness of the nicks in a perforated cut may be set based on a type ofmaterial used for the blank 10, a thickness of the material, conditionsknown to arise during packing, distribution and use, and a type ofproduct to be stored in the carton.

FIG. 2 is a top plan view of a flat blank for a carton including a labelaccording to an example embodiment. The label 2 k is applied to thesecond panel 2 during a finishing process of the blank 10, i.e., afterthe panels of the blank 10 have been cut and the cut patterns have beenperformed to form the cutout 2 g or opening. The first through fifthpanels 1-5 of the blank 10 are built in a desired order from left toright so the application of the label 2 k to each blank can be performedin a single gluing operation during a high speed manufacturing process.FIGS. 1 and 2 show the cut patterns and label applied to the secondpanel 2; however, example embodiments are not limited thereto, and thecut patterns and label may be applied to any of the second through fifthpanels 2-5 depending on a desired configuration of the assembled cartonand/or a configuration of a gluing machine for applying the label 2 k.Furthermore, an order from left to right of the second through fifthpanels 2-5 may itself be varied. For example, as shown in FIG. 8, thesecond panel and the fifth panel may be swapped in the build order suchthat the fifth panel is between the first panel 1 and the third panel 3,and the second panel is at the far widthwise end of the blank 10.

A process of forming a carton from the blank 10 will now be describedwith respect to example embodiments shown in FIGS. 3-7.

As shown in FIG. 3, the foldable crease between the second panel 2 andthe third panel 3 and the foldable crease between the fourth panel 4 andthe fifth panel 5 are folded up to erect the carton into a productloading position. The exterior surface of first panel 1, which includesan adhesive or glue layer, adheres to the interior surface of the fifthpanel 5. Although FIGS. 3-7 show the first panel 1 for descriptivepurposes, the first panel 1 is hidden from view behind the fifth panel 5when the carton is in the product loading position and when the cartonin fully assembled. The product is loaded into the carton in the productloading position with ends of the carton open for insertion of theproduct.

As shown in FIG. 4, the first and second embossed areas 4 a and 4 b andthe first scored area 4 e are folded together as a flap after theproduct is loaded into the main body of the carton to close one of theopenings at the ends of the carton. The flap including the firstembossed areas 4 a and 4 b and the first scored area 4 e (or itscorresponding flap on the opposite side of the panel) is folded firstamong the flaps of the first through fifth panels to provide a siftproof Easy-Open-Reclose carton.

As shown in FIG. 5, the flap including the first and second embossedareas 4 a and 4 b and the first scored area 4 e from FIG. 4 is foldedfirst. The first and second dust flaps 3 a and 5 a are folded in, afteran adhesive or glue pattern is applied to the outside of the flapincluding the first and second embossed areas 4 a and 4 b and the firstscored area 4 e. The tab 1 a is automatically folded with dust flap 5 abecause the exterior surface of the tab 1 a is adhered with adhesive orglue to the interior surface of the first dust flap 5 a. Anotheradhesive or glue pattern is applied to the outside of the folded firstand second dust flaps 3 a and 5 a and the first scored area 4 e, whichhas not been covered by the dust flaps 3 a and 5 a. The first and seconddebossed areas 2 a and 2 b and the first scored area 2 e are foldedtogether as a flap onto the folded dust flaps 3 a and 5 a and the firstscored area 4 e and adhered thereto by the adhesive or glue to create asift proof style carton. The Embossing/Debossing is configured in apattern that allows the flaps to be formed and folded in a desired orgiven pattern such that corresponding areas having matching shapes areadhered together on top of one another.

The above described process for forming the sift proof style cartonpattern is repeated on the opposite end of the carton to form acompletely sift proof carton. Alternatively, the above described processfor forming the sift proof style carton may be performed simultaneouslyon each end of the carton to form a completely sift proof carton Detailsthereof are omitted in the interest of brevity as it will be understoodby one of skill in the art that the same processes are applied to eachend.

FIG. 6 shows the carton in an assembled condition with the sift proofflaps glued and folded at each end thereof. The first panel 1 is gluedon the inside of the fifth panel 5 to create a smooth look and feel,with tab 1 a glued on the inside of dust flap 5 a and tab 1 b glued onthe inside of dust flap 5 b. The second panel 2 is a main body part thatcarries the unique reverse and/or perforated cuts 2 h, 2 i and 2 j, andthe opening 2L created thereby when and peel and reseal label 2 k andthe cutout 2 g is lifted. FIG. 6 is shown without the cutout 2 g so thatthe inside of the carton and the opening 2L can be displayed.

As shown in FIG. 7, when the label 2 k is pulled up it opens the opening2L in the second panel 2 and lifts with it the cutout 2 g if present.The inside of the label 2 k is coated with a reusable and resealableadhesive or glue for the reclosing of the carton and to recreate acompletely sealed sift proof carton. The cutout 2 g adheres to theinside of the label 2 k and fits back into the opening 2L when thecarton is resealed. The edges of the label 2 k around the cutout 2 gadhere to the exterior surface of the second panel 2 to seal and resealthe carton in a sift proof manner. In another example embodiment, thecutout 2 g may be removed and only the label 2 k is used to cover andseal the opening 2L in the carton.

The second panel 2 is the only panel to include a resealable opening inexample embodiments shown in FIGS. 3-7. In another example embodiment,multiple panels may include a resealable opening.

As previously disclosed, the order of the first through fifth panels 1-5may be varied based on a configuration of a gluing or label applicationmachine or a desired configuration of an assembled carton. For example,as shown in FIG. 8 the second panel and the fifth panel may be swappedin the build order of the blank 10 such that the fifth panel is betweenthe first panel 1 and the third panel 3, and the second panel is at thefar widthwise end of the blank 10. Accordingly, in contrast to exampleembodiments described above in which the label 2 k is applied to a topof the box on the second panel 2, the label 2 k is applied to a side ofthe box.

Although example embodiments have been shown and described in thisspecification and figures, it would be appreciated by those skilled inthe art that changes may be made to the illustrated and/or describedexample embodiments without departing from their principles and spirit.

1. A blank for forming a resealable carton, the blank comprising a flatsheet of material having a first surface configured to form an exteriorsurface of the carton and an opposite, second surface configured to forman interior surface of the carton, the sheet of material comprising aplurality of panels, including at least a first panel and a secondpanel, foldably connected in a width-wise direction of the panels,wherein the second panel comprises an opening configured to receive aresealable label.
 2. The blank of claim 1, further comprising third,fourth and fifth panels, which, together with the second panel, form themain body panels of the assembled carton.
 3. The blank of claim 2,wherein the first panel is foldably connected to the second panel andcomprises an adhesive coating to adhere to the fifth panel to form themain body of the carton.
 4. The blank of claim 1, further comprising aresealable label applied to the opening of the second panel to provide aresealable opening of the assembled carton.
 5. The blank of claim 4,wherein the inside of the label is coated with a resealable adhesive forthe reclosing of the assembled carton to form a sealed sift-proofcarton.
 6. The blank of claim 1, wherein the second panel comprises acutout portion corresponding to the opening in the second panel.
 7. Theblank of claim 6, wherein a portion of the cutout portion is foldablyattached to the second panel.
 8. The blank of claim 6, wherein thecutout portion is detached from the second panel.
 9. The blank of claim6, further comprising a label applied to the cutout portion of thesecond panel so that the cutout portion adheres to the inside of thelabel, wherein when the label is pulled up, the label lifts the cutoutportion, thereby providing access to the opening in the second panel,and the cutout portion fits back into the opening when the carton isresealed.
 10. The blank of claim 9, wherein edges of the label aroundthe cutout portion adhere to the exterior surface of the second panel toseal the carton in a sift-proof manner
 11. The blank of claim 6, thecutout portion being formed by a first cut pattern, a second cutpattern, and a third cut pattern, the second cut pattern being offsetfrom the first cut pattern, and the third cut pattern joining the firstcut pattern and the second cut pattern
 12. The blank of claim 11,wherein the first cut pattern is a 50% cut which is cut from theinterior surface of the carton, and the second cut pattern is a 50% cutwhich is cut from the exterior surface of the carton.
 13. The blank ofclaim 12, wherein the third cut pattern comprises a nick pattern toprovide a starting point for opening and lifting the cutout portion.